Apparatus and method for delivering a product into a receptacle

ABSTRACT

An apparatus for delivering a product into a receptacle having a feeding aperture. The apparatus comprises a mixing chamber having a plurality of inlets each configured for separately receiving at least one of a plurality of component materials and at least one outlet, the mixing chamber being configured for forming the product by mixing the plurality of component materials and injecting the product to the feeding aperture via the at least one outlet and a feeding element configured for being secured in a feeding channel for allowing the injecting.

FIELD AND BACKGROUND OF THE INVENTION

The present invention, in some embodiment thereof, relates to packagingof component materials, and more particularly, but not exclusively, tothe mixing and storage of component materials before and during thepackaging.

Various materials are formed by mixing two or more chemical components.For example foam, which is a mixture of isocyanate and polyol, expandsand hardens within about 10-30 seconds. In many cases, a foam dispensinggun is used to generate the foam at the packaging site.

U.S. Pat. No. 3,178,157 by Cole, U.S. Pat. No. 6,691,898 by Hurray etal., and U.S. Pat. No. 5,462,204 by Finn, the disclosures of which areincorporated herein by reference, describe dispensing guns used in themaking of foams, such as urethane foams.

As foam materials harden within a short time, remnants of the foam mayharden within the dispensing apparatus and clog flow passageways. Onesolution to the clogging of passages is to include a solvent flushingpath in the gun, which provides a solvent that cleans out portions ofthe gun that require cleaning, after every use. U.S. Pat. No. 4,262,847by Stitzer et al. describes one such gun.

Other dispensing guns include a mechanical cleaning device that passesthrough the mixing chamber between uses. U.S. Pat. No. 5,405,083 byMoses, the disclosure of which is incorporated herein by reference,describes another dispensing gun in which, a disposable mixing tube isreplaced, each time the gun is used.

U.S. Pat. No. 5,429,308 to Brown describes a mixing gun having areplaceable nozzle including a mixing chamber. Those parts of the gunthat come in contact with the mixed chemicals are included in thereplaceable nozzle. In the non-disposable part of the gun, respectivevalves are used to control the flow of each of the chemical componentsinto the mixing chamber.

U.S. Pat. No. 6,375,096 by Rashidi describes a foam gun with adisposable nozzle attachment including a mixing chamber in which thechemicals mix. The disposable nozzle includes one way valves for each ofthe chemicals entering the nozzle attachment, so as to prevent backflowof the chemicals into the non-disposable part of the gun. The cost ofthe disposable nozzle attachments is not negligible and theirreplacement is time consuming. It is therefore desired to reduce andeven eliminate the need for replacement of the disposable nozzleattachments, without incurring the costs and inconvenience involved in asolvent flushing system or a mechanical cleaning system.

U.S. Pat. No. 4,262,848 to Chabria describes a dispensing gun, whichdoes not have a mixing chamber at all. The chemicals are mixed a shortdistance distal from the dispensing gun. Such mixing in the air, mayresult in a reduced quality of the foam. A flexible extension issuggested to be used to separately lead the chemicals before they aremixed to a location forward of the gun.

SUMMARY OF THE INVENTION

The present invention, in some embodiments thereof, relates to thedelivery of fluids comprising a plurality of fluidic components into oneor more receptacles, by directing the fluidic components into a mixingchamber located at a proximity of the receptacle. In the mixing chamber,the fluidic components are mixed and/or react together to form the fluidthat is delivered into the receptacle.

According to an aspect of some embodiments of the present inventionthere is provided an apparatus for delivering a product into areceptacle having a feeding aperture. The apparatus comprises a mixingchamber having a plurality of inlets each configured for separatelyreceiving at least one of a plurality of component materials and atleast one outlet, the mixing chamber being configured for forming theproduct by mixing the plurality of component materials and injecting theproduct to the feeding aperture via the at least one outlet and afeeding element configured for being secured in a feeding channel forallowing the injecting.

Optionally, the distance between the mixing chamber and the apertureduring the injecting is less than 5 centimeters.

Optionally, each the inlet being separately connected to a hydraulictube configured for conducting respective the component material from apump, wherein the distance between the mixing chamber and the pump ismore than 10 centimeters.

Optionally, each the inlet being separately connected to a hydraulictube configured for conducting respective the component material from acontainer, wherein the distance between the mixing chamber and thecontainer is more than 10 centimeters.

Optionally, at least one of the feeding element and the mixing chamberis detachable.

Optionally, the distance between the mixing chamber and the apertureduring the injecting is less than 1 centimeter.

Optionally, the feeding element is configured for containing the mixingchamber.

Optionally, the product is formed as an outcome of a chemical reactionbetween at least two of the plurality of component materials.

Optionally, the mixing chamber having a volume of less than 5 cubicmillimeter for performing the mixing.

More optionally, the apparatus further comprises a motor unit configuredfor motivating at least one of the mixing chamber and the receptacle tothe distance before the injecting.

More optionally, the apparatus further comprises a control unitconfigured for synchronizing between the motivating and the injecting.

Optionally, the apparatus further comprises a pumping unit configuredfor directing the plurality of component materials into the mixingchamber, the directing being controlled by at least one userinstruction.

Optionally, the apparatus further comprises a feeding element configuredfor supporting the positioning of the aperture in front of the at leastone outlet before the injecting.

More optionally, the receptacle is a member of a roll of a plurality ofreceptacles connected to a feeding channel, further comprising a motorunit configured for conducting the feeding element in the feedingchannel for supporting the positioning of respective the aperture ofeach member of the roll.

More optionally, the feeding element comprises a wedge configured forcutting the feeding channel during the conducting.

According to an aspect of some embodiments of the present inventionthere is provided a roll of a plurality of receptacles for storing aproduct. The roll comprises a plurality of receptacles each comprises acontainer configured for storing the product of a mixture of a pluralityof components and a feeding aperture configured for receiving theproduct. The apparatus further comprises a feeding channel configuredfor covering each the feeding aperture and supporting the positioning ofeach the feeding aperture in front of an injection unit having a mixingchamber during a filling of respective the container.

Optionally, the feeding channel is configured for being cut to allow thefilling of respective the container with the product.

According to an aspect of some embodiments of the present inventionthere is provided a method for creating a packaging element. The methodcomprises using a feeding element for feeding a receptacle having afeeding aperture to a distance of less than 5 centimeter from aninjection unit having a mixing chamber, separately conveying a pluralityof component materials into the mixing chamber, mixing the plurality ofcomponent at the mixing chamber to form a mixing product, injecting themixing product via the feeding aperture into the receptacle, andallowing the mixing product to solidified in the receptacle according toa shape of a packaged item.

Optionally, the method further comprises using the receptacle with thesolidified mixing product for packaging the packaged item withoutclosing the aperture.

More optionally, the feeding comprising actuating a roll of a pluralityof receptacles to allow the positioning of the receptacle in front aninjection unit performing the injecting.

Optionally, the method further comprises getting at least one userinstruction, before the separately conveying and separately conveyingthe plurality of component materials according to the at least one userinstruction.

Optionally, the plurality of component materials comprises isocyanateand polyol, the mixing product comprises polyurethane.

Unless otherwise defined, all technical and/or scientific terms usedherein have the same meaning as commonly understood by one of ordinaryskill in the art to which the invention pertains. Although methods andmaterials similar or equivalent to those described herein can be used inthe practice or testing of embodiments of the invention, exemplarymethods and/or materials are described below. In case of conflict, thepatent specification, including definitions, will control. In addition,the materials, methods, and examples are illustrative only and are notintended to be necessarily limiting.

Implementation of the method and/or system of embodiments of theinvention can involve performing or completing selected tasks manually,automatically, or a combination thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

Some embodiments of the invention are herein described, by way ofexample only, with reference to the accompanying drawings. With specificreference now to the drawings in detail, it is stressed that theparticulars shown are by way of example and for purposes of illustrativediscussion of embodiments of the invention. In this regard, thedescription taken with the drawings makes apparent to those skilled inthe art how embodiments of the invention may be practiced.

In the drawings:

FIG. 1 is a schematic illustration of an exemplary apparatus having amixture chamber designed for mixing a plurality of component materialsto form a fluid, and for delivering the fluid into one or morereceptacles placed at a proximity of the mixture chamber, according tosome embodiments of the invention; the apparatus is shown to receive thecomponent materials from two reservoirs.

FIG. 2 is a schematic illustration of an apparatus through whichcomponent materials flow for forming a product, and through which theproduct is delivered into a receptacle, according to some embodiments ofthe invention;

FIG. 3 is a schematic illustration of an exemplary apparatus for forminga product from the component materials and delivering the product into areceptacle, where the apparatus is characterized by external gear pumps,according to some embodiments of the invention;

FIG. 4 is a schematic illustration of two receptacles, according to someembodiments of the present invention;

FIGS. 5A and 5B are schematic illustrations of an apparatus for forminga product from the component materials and delivering the product into aplurality of receptacles, according to some embodiments of theinvention;

FIGS. 5C and 5D are schematic illustrations of a feeding element in arail of a receptacle and an exemplary apparatus for forming a productfrom the component materials, according to some embodiments of theinvention;

FIG. 5E is a schematic illustration of an exemplary apparatus thatcomprises the mixing chamber and the feeding channel of FIGS. 5C and 5D,according to some embodiments of the invention;

FIG. 5F is a schematic illustration of a feeding element in a rail of areceptacle and an exemplary apparatus for forming a product from thecomponent materials, according to some embodiments of the invention; and

FIG. 6 is a flowchart of a method for delivering a product intoreceptacles, according to some embodiments of the invention.

DESCRIPTION OF SPECIFIC EMBODIMENTS OF THE INVENTION

The present invention, in some embodiment thereof, relates to packagingof component materials, and more particularly, but not exclusively, tothe mixing and storage of component materials before and during thepackaging.

As used herein, to mix two or more materials means to induce a chemicalreaction, to blend, and/or to bring the materials into contact with eachother. As used herein, the term “delivery time” refers to the timebetween the formation of a product, from mixing two or more componentmaterials, and the delivery of the product to a receptacle.

According to an aspect of some embodiments of the present invention, anapparatus for forming a fluidic product by mixing fluidic componentmaterials together and for delivering the newly formed product to areceptacle is provided. The mixing of the component materials occurs ina mixing chamber that is positioned at proximity of the receptacle—forexample, less than 5 centimeters from the receptacle, for examplebetween 0.01 and 2 millimeters. In such a manner, the product isdelivered into the receptacle substantially immediately after themixing. For example, the product may be delivered to the receptacleapproximately between 1 and 50 milliseconds after being formed. Theapparatus comprises a feeding element that allows the feeding of one ormore receptacles toward a position about the mixing chamber. Optionally,in use, the feeding element is placed in a feeding channel that isattached to the one or more receptacles. The feeding channel supportsthe feeding of the one or more receptacles in front of the mixingchamber that delivers the product thereto.

The short time between the mixing of the component materials within themixing chamber and the delivery of the product to the receptacle makesthe apparatus useful for mixing isocyanate and polyol, for forming anddelivering polyurethane. Polymers, such as polyurethane, are known tosolidify relatively short time after being formed.

The short time between the formation and the delivery of the productallows the delivery of the product to take place when the product isstill in fluid form. This may reduce or eliminate any clogging which maybe formed as a result of the hardening of packaging material inside theapparatus.

Optionally, the above apparatus is designed for being conveyed by amotor unit to a position at which a delivering element of the apparatusis aligned with an inlet, such as a receiving aperture, of thereceptacle.

Optionally, the above apparatus is designed for moving the receptacle,for example by using rollers, to a point in which the inlet of thereceptacle is aligned with the delivering element, such as a nozzle, ofthe apparatus. For example the apparatus and/or receptacle may be movedso that the delivering element is aligned with the inlet. Optionally,the apparatus and/or receptacles may be moved relative to each other, inorder to deliver the product to a plurality of receptacles, one by one.

According to an aspect of some embodiments of the present invention, areceptacle is provided. The receptacle includes a container, designedfor storing a product, an inlet, designed for receiving a product in afluidic state, and a feeding channel, for supporting the motivation ofthe receptacle toward an element that delivers the product into thereceptacles. Optionally, the inlet is covered by the feeding channel. Inuse, the feeding channel may be torn, for example by a wedge, to allow adelivering element to directly access the inlet. The inlet may be sealedafter being opened, for example by heating the open sides thereof andjoining them together.

Before explaining at least one embodiment of the invention in detail, itis to be understood that the invention is not necessarily limited in itsapplication to the details of construction and the arrangement of thecomponents and/or methods set forth in the following description and/orillustrated in the drawings and/or the Examples. The invention iscapable of other embodiments or of being practiced or carried out invarious ways.

FIG. 1 is a schematic illustration of an apparatus 110 for mixing aplurality of component materials at a proximity of a receptacle 112 thatis designed for storing the product of the mixing, according to someembodiments of the invention. The apparatus 110 is designed to beattached and/or contained in a feeding element that allows the feedingof one or more receptacles toward a position about the mixing chamber,for example to a position at a distance of less than 5 millimeter.

In FIG. 1, apparatus 110 separately receives a plurality of componentmaterials 104, 108 from respective reservoirs 102, 106. Componentmaterials 104 and 108 are conveyed to a mixing chamber 114 in whichcomponent materials 104 and 108 are mixed. The conveying is done byconveyers, for example pipes, tubes, and capillaries. The product of themixing is delivered to a receptacle 112, which is positioned atproximity of the mixing chamber 114, optionally in a distance of lessthan 5 centimeters therefrom.

Optionally, the mixing chamber 114 comprises a plurality of inlets eachconfigured for receiving another component material and one or moreoutlets configured for injecting the product via an aperture in thereceptacle. Optionally, the diameter of the aperture is less than 5centimeters. Optionally, the diameter of the aperture is less than 2centimeters. Optionally, the diameter of the aperture is less than 1centimeter. As the component materials which are conducted via theplurality of inlets may accumulate in a manner that blocks the mixingchamber 114 the inlets and/or the outlets of the mixing chamber 114, themixing chamber 114 may be detachable. In such a manner, the mixingchamber 114 may be replaced in order to ensure a continuous functioningof the apparatus 110. Optionally, the apparatus 110 and/or the mixingchamber 114 comprises one or more coupling fitments that allows thereplacement, cleaning, and/or repositioning of the mixing chamber 114.Optionally, the apparatus 110 may be detachable and/or replaceable,allowing the user to maintain a system that uses the apparatus 110 forfilling receptacles, such as a packaging system.

Optionally, apparatus 110 is connected to a motor unit that is designedto move apparatus 110 to face receptacle 112 or vice versa. Such anactuation allows apparatus 110 to deliver the product into receptacle112, which is optionally a member of a roll of a plurality ofreceptacles, without a conduit or any other piping device. For example,apparatus 110 may be placed on a rail and moved along the rail by amotor. Optionally, apparatus 110 includes actuators for the moving oneor more receptacles 112 into a delivery position, in which the productis delivered into receptacle 112. As further described below, apparatus110 may include rollers for actuating the roll's receptacles, forexample the receptacle shown at 112.

As mixing chamber 114 is brought to proximity of receptacle 112, thedelivery time of the mixed product is reduced. Apparatus 110 maytherefore be used to mix fluids which harden and/or solidify shortlyafter being mixed. Reducing the product's delivery time allows thedelivery of the product to take place when the product is still fluidic.In such a manner, the clogging of the product conveyers is reduced oreliminated.

The presence of apparatus 110 allows first and second componentmaterials 104 and 108 to be stored separately. In such a state, each oneof the component materials 104 and may be contained in their respectivereservoirs for an extended period of time, such as half a year, a yearand/or any other shelf life at inert state and/or before crystallizing.Therefore, reservoirs 102 and 106 may hold large amount of componentmaterials.

According to exemplary embodiments of the present invention, apparatus110 is designed for forming polyurethane. In such embodiments, the firstcomponent material 104 is isocyanate, and the second component material108 is polyol. According to exemplary embodiments of the presentinvention, apparatus 110 may be used for forming polyurethane bags forpackaging. In use, the apparatus 110 may be used for mixing componentsin a liquid state of aggregation to form polyurethane foam which isspread around the shape of a packaged item. The mixture solidified toform a hardened wraparound that is adjusted to the dimensions of thepackaged item.

It must be noted that apparatus 110 is not limited to be used with anyspecific component materials. Apparatus 110 (and consequently apparatus200 of FIG. 2, apparatus 300 of FIG. 3, and apparatus 500 of FIG. 5) maybe used with many component materials, to form a large range of desiredproducts.

Optionally, more than two component materials are needed for forming thedesired product. Apparatus 110 is optionally designed for receiving morethan two component materials and housing a mixing of the componentmaterials, for obtaining the desired product. Optionally, the componentmaterials may form the desired product through a series of sequentialmixing processes. For example, a first component material combines witha second component material, forming an intermediate product, and theintermediate product combines with a third component material, to formthe desired product.

FIG. 2 is a schematic illustration of an apparatus through whichcomponent materials flow for forming a product and, and through whichthe product is delivered into a receptacle, according to someembodiments of the invention.

Apparatus 200 includes conveyers 202 and 204, for receiving componentmaterials from reservoirs and conveying the component materials tomixing chamber 206, a mixing chamber 206, for mixing the componentmaterials, and a delivering element 208, such as a nozzle, for directingthe product formed in mixing chamber 206 to the receptacle. Optionally,conveyers 202 are pipes, tubes, capillaries, or a combination thereof.

Optionally, apparatus 200 further includes a pumping unit, which forexample includes pumps 210 and 212. Pumps 210 and 212 are placed alongconveyers 202 and 204, respectively, for regulating the flow of thecomponent materials out of the reservoirs and into mixing chamber 206.Optionally, pump drivers 214 and 216 are provided, for driving pumps 210and 212, respectively. Optionally, pump drivers 214 and 216 are motors.Optionally, a control unit (not pictured) is provided to control theoperation of pump drivers 214 and 216, and consequently, of pumps 214and 216. Optionally, the control unit is controlled by a user, and thepumping unit is controlled by at least one user instruction.

Conveyer 202 is connected to a reservoir, for example reservoir 102 ofFIG. 1, at an entry point 202 a, for receiving a component material, forexample component material 104 of FIG. 1. The component material flowsthrough conveyer 202 and into mixing chamber 206. Similarly, a secondcomponent material, for example component material 108 of FIG. 1, flowsto mixing chamber 206 through conveyer 204. Optionally, at least oneflow parameter of the component materials is regulated by pumps 210 and212. In mixing chamber 206, a mixing between the component materialstakes place, and a product is formed. The product exits apparatus 200through delivering element 208, and enters the receptacle where theproduct is to be stored. Since the flow of the product out of mixingchamber 206 through delivering element 208 is related to the flow of thecomponent materials into mixing chamber 206, the flow properties of theproduct through delivering element 208 depends on the settings of pumps210 and 212. The flow of the product out of delivering element 208 istherefore regulated by pumps 210 and 212.

Optionally, pumps 210 and 212 control the pressure at which thecomponent materials are directed into mixing chamber 206. Optionally,pumps 210 and 212 control the quantities of the component materialsdirected into mixing chamber 206.

Optionally, pumps 210 and 212 are external gear pumps. Optionally pumps210 and 212 are internal gear pumps. Optionally pumps 210 and 212 aregerotor pump. Optionally pumps 210 and 212 are peristatic pump.Optionally pumps 210 and 212 are positing displacement pumps. Pumps 210and 212 may be placed at any location that allows them to control theflow of the component materials, for example, anywhere along pipes 202and 204, respectively.

Optionally, mixing chamber 206 is constructed according to the mixingchamber described in PCT Applications WO2005IL00355 and WO2005IL00356 byMalik et al., which are herein incorporated by reference. According tosome embodiments of the present invention, mixing chamber 206 ischaracterized by a small volume, for example 20 mm³. A small-sizedmixing chamber may reduce the time between the formation of the desiredproduct and the delivery of the product into the receptacle.

Optionally, delivering element 208 is an integral part of mixing chamber206. Optionally, delivering element 208 is an aperture on the surface ofmixing chamber 206, through which the product formed in mixing chamber206 leaves apparatus 200. Optionally, delivering element 208 comprises ahollow tubular element, such as a needle, for injecting the product viathe inlet of the receptacle. Optionally, delivering element 208 is anarrow element having a cross sectional area of between 0.5 and 1 mm².Optionally, delivering element 208 partially or fully protrudes fromapparatus 200. Protruding delivering element 208 may enter thereceptacle, for example through an inlet of the receptacle. In such amanner, protruding delivering element 208 delivers the product to thereceptacle from the inside of the receptacle, and therefore reduces oreliminates a spillage of the product during delivery. A narrowdelivering element 208 may produce a precise delivery of the productinto the receptacle, by causing the product to exit apparatus 200 at anarrow stream.

According to some embodiments of the present invention, a conveyer isprovided for each component material. Optionally, a pump is alsoprovided for each component material. For example, if three, four, orsix component materials are needed to be mixed in order to form adesired product, then three, four, or six conveyers are provided, suchthat each conveyer is connected to a different reservoir. Optionally,three, four, or six pumps are provided, each pump regulating the flow ofa different component material.

FIG. 3 is a schematic illustration of an apparatus 300 for forming aproduct from the component materials and delivering the product into areceptacle, where the apparatus is characterized by external gear pumps,according to some embodiments of the invention. Apparatus 300 is anembodiment of apparatus 110 of FIG. 1, and of apparatus 200 of FIG. 2.

Apparatus 300 includes the same elements and units as apparatus 200depicted in FIG. 2. Apparatus 300 is an exemplary embodiment ofapparatus 200, as apparatus 300 is characterized by a first and a secondexternal gear pumps.

An external gear pump is characterized by two gears connected to eachother. One of the gears is rotated by a user, either manually orautomatically, for example through a motor. The connection between thegears causes the second gear to rotate as well. The rotation of thegears forces the fluid to flow from the entrance area of the pump to anoutlet area of the pump. The rate of rotation of the gears affects thepressure at which the fluid enters and exits the pump.

An exemplary external gear pump measures about 2 cm by 3 cm by 4 cm.This pump pumps a fluid of a viscosity of about 200 mPa×s out of aconveyer, for example conveyer 202, and into mixing chamber 206, at apressure which may be varied between about 5 BAR and 15 BAR, leading thenewly formed product out of delivering element 208 at a pressure between5 and 15 BAR. The fluid of viscosity 200 mPa×s is, for exampleisocyanate, which is a typical component material of packaging material.

A first external gear pump is associated with conveyer 202. The entrancearea of first external pump is connection point 202 b between conveyer202 and pump cover 302, and the outlet area of the first external pumpis the continuation of conveyer 202. The first external gear pumpincludes a pump cover 302 to house the two interconnected gears, a gearcasing 304, to connect the pump cover to the continuation of conveyer202, and a drive shaft 306, which is connected to one gear and isdesigned for rotating the one gear. Optionally, the first external gearpump also includes a motor-gear coupling element 308, designed forcoupling drive shaft 306 to a motor, and allowing the motor to apply atorque upon drive shaft 306, which in turn applies a torque upon one ofthe gears. For example, motor-gear coupling element may be used tocouple drive shaft 306 to pump driver 214 shown in FIG. 2.

Similarly to the first external gear pump, a second external gear pump,associated with conveyer 204, is characterized by a second pump cover310, a second gear casing 312, a second drive shaft 314, and optionallya second motor-gear coupling 316.

As the gears of the first external gear pump are rotated, firstcomponent material 104 contained in reservoir 102 of FIG. 1 is directedthrough conveyer 202 into pump cover 302. The gears within pump cover302 direct the component material via gear casing 304 to thecontinuation of pipe 202 and to mixing chamber 206. In a similar manner,second component material 108, contained in reservoir 106 of FIG. 1,reaches mixing chamber 206, and a mixing between the first and secondcomponent materials occur, to form the desired product. The productexits mixing chamber 206, flows through delivering element 208, andenters the receptacle.

It should be noted that such an external gear pump builds up arelatively high pressure in a relatively small mixing chamber 206.

FIG. 4 is a schematic illustration of two receptacles, according to someembodiments of the present invention.

Receptacle 400 is characterized by an feeding aperture 402, designed forreceiving a product, a container 403, for storing the product, and afeeding channel 404 for covering feeding aperture 402 and supporting themotivation of receptacle 400 toward a filling apparatus, such asapparatus 110 of FIG. 1, apparatus 200 of FIG. 2, and/or apparatus 300of FIG. 3.

Optionally, feeding aperture 402 is positioned on the perimeter of thecontainer and allows the delivering of the product after receptacle 400has been moved to align feeding aperture 402 with a filling apparatus.According to some embodiments of the present invention, feeding channel404 is interposed between feeding aperture 402 and the fillingapparatus, and therefore prevents access to feeding aperture 402 by thefilling apparatus. Optionally, feeding channel 404 is designed to betorn, for example by a wedge, such as a blade, that is connected to thefilling apparatus, during the delivery process, as described below, inFIGS. 5A and 5B. Such a tear allows access by a delivering element ofthe filling apparatus to feeding aperture 402. Optionally, the inlet isclosed and the product is delivered to receptacle 400 after the feedingaperture 402 is punctured, for example using the delivering element.Optionally, feeding aperture 402 may be sealed after the product'sdelivery, for example by heating the sides of feeding aperture 402 to atemperature of about 120°, causing a partial melting of the heatedareas, and joining the sides together. Optionally, the melted materialis a high-density polyethylene (PEHD).

Feeding channel 404 is tubular and is designed for being traversed, forexample by feeding element, such as a rod or a rail. Optionally, feedingchannel 404 is replaced by a series of loops designed to be traversed bythe feeding element. The feeding element may enter feeding channel 404through opening 406, thereby actuating receptacle 400 to face thefilling apparatus, which delivers a product to receptacle 400. Theactuating may be achieved, for example, by supporting the motivation of,or constraining the movement of receptacle 400 along the feedingelement.

Optionally, receptacle 400 is collapsible. Optionally, receptacle 400 ismade out of PEHD. Optionally, receptacle 400 is rigid. Optionally,receptacle 400 is shaped to determine the shape of a product, likepackaging material, which solidifies shortly after being formed by thecomponent materials thereof. It should be noted that as the product isinjected into a receptacle having a relatively limited feeding aperture,optionally with a diameter of less than 2 centimeters, the receptacle400 may not be seamed, welded, and/or otherwise closed. The product,which is injected in a fluid state of aggregation and solidified in thereceptacle to a solid state of aggregation does not, or substantiallydoes, not extend beyond the sides of the walls of the receptacle 400.The product solidifies before or substantially before it extends beyondthe sides of the walls of the receptacle 400 and therefore the closingof the receptacle 400 may not be required in order to create a packagingelement therefrom.

Optionally, receptacle 400 is used as a packaging element, to be filledwith packaging material—for example polyurethane. Optionally, receptacle400 is used as a polyurethane packaging element.

According to some embodiments of the present invention, a roll 401 isprovided, in which receptacle 400 is joined on a side thereof to asecond receptacle 408, having an inlet 412, and feeding channel 414. Onthe side that is common to receptacles 400 and 408, a line ofperforations 410 is optionally provided, in order to allow an easyseparation between the receptacles, following the product delivery tothe receptacles. Optionally, channels 404 and 414 are joined together toassemble a central feeding channel. Optionally, the roll includes aplurality of receptacles joined at the sides and assembling the centralfeeding channel. The roll is optionally fed to a filling apparatus,which delivers a product to the receptacles, by inserting a feedingelement into opening 406 of feeding channel 404. Optionally, theapparatus moves along the feeding element and delivers the product toeach receptacle in turn. Optionally, the apparatus is fixed, and thereceptacles are moved along the feeding element toward the apparatus, sothat the apparatus delivers the product to each receptacle in turn, asillustrated below (FIGS. 5A and 5B).

FIGS. 5A and 5B are schematic illustrations of an apparatus 500 with afeeding element 502 for forming a product from component materials anddelivering the product into a plurality of receptacles, according tosome embodiments of the present invention. FIG. 5A is a front view ofapparatus 500, and FIG. 5B is an isometric view of apparatus 500.

Apparatus 500 includes all the elements of apparatus 300, for forming adesired product and delivering to a receptacle, the feeding element 502,designed for being inserted into a feeding channel 404 described in FIG.4, and rollers 504, for moving the receptacles along feeding element502. Optionally feeding element 502 is a rod or a rail. Optionally,feeding element 502 includes a wedge, such as a blade wedge, for exampleas shown at 506 of FIG. 5A. The wedge cuts feeding channel 404, therebyallowing continued movement of the receptacles along rod 502.Optionally, the blade also cuts open the inlets of the receptacles,thereby allowing feeding of the receptacles and the delivery of theproduct to the receptacles.

Optionally, apparatus 500 further comprises a sealing device (notshown), for sealing the receptacles once the product delivery iscomplete. Optionally, sealing device seals the receptacles, by heatingthe open sides of the inlet and joining them together, as explainedabove. Optionally, the sealing device includes a resistor based heater.

In FIGS. 5A and 5B, feeding element 502 is inserted into a centralfeeding channel of a roll which includes receptacles 400 and 408.Rollers 504 move the receptacles in direction 508, along feeding element502. The wedge 506 on feeding element 502 cuts the central feedingchannel, to allow access to feeding aperture 402 by apparatus 500, andto prevent the kit from getting stuck on feeding element 502, thusensuring that the receptacles can continue to be moved. Optionally, thewedge 506 on feeding element 502 also cuts open feeding aperture 402, iffeeding aperture 402 is closed. When a delivering element of apparatus500 is aligned with open feeding aperture 402, the rollers stop moving,therefore stopping the movement of the receptacles and the delivery ofthe product takes place, as previously described. After the delivery toreceptacle 400 is complete, the rollers resume their movement, and thereceptacles resume moving in direction 508. Feeding aperture 402 passesby sealing device, and receptacle 400 is sealed, in the manner describedabove. As the movement continues, inlet 412 of receptacle 408 is cutopen, and the process is repeated.

Optionally, the receptacles are fixed, and apparatus 500 moves along afeeding channel, such as a rail, inserted into the central feedingchannel of the roll of receptacles, to deliver the product to thereceptacles. Optionally, rollers 504 are substituted by different meansfor moving the receptacles, such as pneumatic manipulators.

Optionally, the product delivery is synchronized with the movement ofthe receptacle. This may be done, for example, by connecting flowcontrol units to rollers 504. Exemplary flow control units are the pumpsof apparatus 500 and/or pump drivers 214 and 216, as described above.According to some embodiments of the present invention, product deliveryis not executed when rollers 504 move. Optionally, a control unit 512 isprovided, to control the operation of rollers 504 and of pump drivers214 and 216.

Optionally, control unit 512 is programmable by a user, in order the setthe parameters of the synchronization between rollers 504 and pumpdrivers 214 and 216. For example, the user may change, via control unit512, the speed of rotation of the rollers and/or the torque provided bypump drivers 214 and 216 to the pumps of apparatus 500. Optionally, ifapparatus 500 moves and the receptacles are fixed, the motor unit formoving apparatus 500 is synchronized with pump drivers 214 and 216.Optionally, control unit 512 controls the operation of the motor unitfor moving apparatus 500 and of pump drivers 214 and 216. Optionally,control unit 512 is programmable by a user, in order the set theparameters of the synchronization between the motor unit and pumpdrivers 214 and 216. For example, the user may change, via control unit512, the speed at which apparatus 500 moves and/or the torque providedby pump drivers 214 and 216 to the pumps of apparatus 500.

Optionally, control unit 512 is designed to receive at least oneinstruction from a user, for example through a computer program.Optionally, the instruction is given in order to set quantities and/orpressures of the component materials directed into the mixing chamberand the quantity and/or the pressure of the product formed by thecomponent materials as the product is directed into the receptacles.Optionally, control unit 512 includes a computer.

Optionally, apparatus 500 includes a sensor placed next to deliveringelement 208, shown in FIGS. 2 and 3. The sensor detects the position offeeding aperture 402 in relation to the outlet of the mixing chamber,which may be referred to herein as a delivering element 208. Optionally,the sensor is designed to send a signal to control unit 512, whenfeeding aperture 402 is in a position suitable for product delivery byapparatus 500, and cause the moving means to stop the movement of thereceptacles, and/or the movement of apparatus 500.

Optionally, the sensor is part of an image capturing device, such as acharge coupled device (CCD) sensor, or a complementary metal oxidesemiconductor (CMOS) sensor. The position of the feeding aperture 402 isdetermined according to an analysis of the image captured by the sensor.The analysis is optionally performed by control unit 512.

Optionally, the sensor is part of a photo detector, which includes alight source, and a sensor. Light emitted by the light sourceilluminates the receptacle, and is reflected back to the sensor. Whenthe emitted light illuminates feeding aperture 402, light is reflectedin a different manner toward the sensor. For example, a higherpercentage, or a lower percentage may be reflected. The position of theinlet is determined according to the change in the properties of lightdetected by the sensor.

Reference is now made to FIGS. 5C and 5D which are schematicillustrations of a feeding element 601 in a feeding channel 602 of areceptacle 613 and an exemplary mixing chamber 607 for forming a productfrom the component materials which is connected to hydraulic tubes 604and designed to be contained in the feeding element, according to someembodiments of the invention. Reference is also made to FIG. 5E, whichis a schematic illustration of an exemplary apparatus 650 that comprisesthe mixing chamber 607 and the feeding channel 602, according to someembodiments of the invention. In the exemplary apparatus 650, the mixingchamber 607 is contained in the feeding channel 602. Optionally, thehydraulic tubes 604 have valves for adjusting the streaming of thematerial components therein. The hydraulic tubes may be flexible, rigid,and/or having flexible and rigid segments. The hydraulic tubes may becovered by one or more heating sleeves to maintain the temperature ofthe streamed component materials. Optionally, different tubes are coatedwith different heating sleeves to maintain different temperatures ofdifferent streamed component materials.

The feeding element 601 is optionally defined as described above inrelation to feeding element 502. In addition, the feeding element 601 isdesigned to contain apparatus 603 that is depicted in FIG. 5D, forexample as depicted in FIG. 5F. As depicted in FIG. 5D, apparatus 603comprises two inlets 606 configured for separately receiving differentcomponent materials for injecting the product via an aperture in thereceptacle, such as the inlet shown at 412 of FIG. 4. The apparatus 603comprises a mixing chamber 607 for mixing the received componentmaterials, for example as described above in relation to FIG. 1. Eachone or the inlets 606 is connected to a conducting element 608, such asa conveyer, for example a tube, which is designed to conduct therespective component material thereto. The conducting element 608 isstretched along the feeding element 601. The feeding element 601 has aninjecting aperture (not shown) for allowing the apparatus 603 to injectthe product via the receptacle's aperture. In such a manner, the productis injected directly to the receptacle 613. The direct injection reducesthe waste of component materials as it assures that the product isinjected directly into the receptacle 613. In addition, the cleaningfrequency may be reduced.

Optionally, the apparatus 603 comprises a blade 651 for cutting the feedchannel 404 to allow the aforementioned injection. As described above,the feeding channel 404 is designed to be torn by the blade 651 duringthe delivery process. Such a tear allows the delivering of the productvia the delivering element of the mixing chamber 607 to the receptacle613.

It should be noted that the hydraulic tubes 604 allows the positioningof the mixing chamber in a distance from the pumps and/or thecontainers. For example, the distance may be 1, 2, 3, 4, 5, 10, 20, 30,40, 50, 100, 200, and 500 centimeter(s). In such a manner, the mixingchamber 607 can easily replaced when plugged. Furthermore, the hydraulictubes 604 allows the positioning of the mixing chamber 607 in feedingelements having different structures which are adapted for feedingdifferent receptacles. In such a manner, different feeding elements maybe attached to the apparatus 603 to allow the feeding of receptaclesfrom different materials and/or of various forms.

FIG. 6 is a flowchart of a method 700 for delivering a product intoreceptacles, according to some embodiments of the invention.

At 702, component materials of the product are provided, for examplesinside reservoirs. Optionally, the component materials are the componentmaterials needed for forming packaging material, as described above.Optionally, two component materials are needed for forming the desiredproduct. Optionally, more than two component materials are needed forforming the desired product.

At 704, an access is opened to the receptacle. For example, a closedinlet of the receptacle may be opened. Optionally the feeding aperture402 is punctured by a needle, as described above. Optionally, thefeeding aperture 402 is cut open by a blade, as described above.Optionally, a channel covering the feeding aperture 402 is cut, forexample as shown at numeral 651 in FIG. 5E and described above.

At 706, at least one user instruction is received. Optionally, theinstruction is sent via a control unit to a pumping unit, as describedabove. Optionally, the instruction is used to set one or more flowparameters of one or more component materials. For example, a pressureand/or a quantity of a component material is chosen.

At 708, the component materials flow out of the reservoirs and arereceived conveyers described above. Optionally, the component materialsare pumped out of the reservoirs and into the conveyers. At this stage,the component materials do not come in contact with each other.

At 610, the flow of the component materials is adjusted, if needed,according to the user instruction of 706. The adjustment may beperformed, for example by monitoring the flow properties of thecomponent materials and/or the product, and changing the flowproperties, according to the user instruction. This may be accomplished,for example, by changing a torque provided by a pump driver to a gear ofan external gear pump, as described above.

At 712, the component materials reach a mixing chamber. In the mixingchamber, the component materials are mixed, and a product is formed, asdescribed above.

At 714, the product formed in the mixing chamber is directed by adelivering element to the receptacle, for example through the inletopened at 604.

At 718, another receptacle is moved into position, and the process isrepeated, starting from step 704.

Method 700 may be used with the apparatuses shown in FIGS. 1, 2, 3, 5A,and 5B. Method 700 is useful for quickly forming and delivering productswhich harden and/or solidify within a short period of time after beingformed, and need to be delivered to a receptacle while still in fluidform. Such a product is packaging material, which solidifies about 10-30seconds after being formed. Method 700 is also useful for forming anddelivering products that are affected by contact with air, while thecomponent materials of the products are not affected by being exposed toair.

It is expected that during the life of a patent maturing from thisapplication many relevant products and component materials will bedeveloped and the scope of the term “product” and “component material”is intended to include all such new technologies a priori.

As used herein the term “about” refers to ±10%.

The terms “comprises”, “comprising”, “includes”, “including”, “having”and their conjugates mean “including but not limited to”.

The term “consisting of” means “including and limited to”.

The term “consisting essentially of” means that the composition, methodor structure may include additional ingredients, steps and/or parts, butonly if the additional ingredients, steps and/or parts do not materiallyalter the basic and novel characteristics of the claimed composition,method or structure.

As used herein, the singular form “a”, an and the include pluralreferences unless the context clearly dictates otherwise. For example,the term “a compound” or “at least one compound” may include a pluralityof compounds, including mixtures thereof.

Throughout this application, various embodiments of this invention maybe presented in a range format. It should be understood that thedescription in range format is merely for convenience and brevity andshould not be construed as an inflexible limitation on the scope of theinvention. Accordingly, the description of a range should be consideredto have specifically disclosed all the possible subranges as well asindividual numerical values within that range. For example, descriptionof a range such as from 1 to 6 should be considered to have specificallydisclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numberswithin that range, for example, 1, 2, 3, 4, 5, and 6. This appliesregardless of the breadth of the range.

Whenever a numerical range is indicated herein, it is meant to includeany cited numeral (fractional or integral) within the indicated range.The phrases “ranging/ranges between” a first indicate number and asecond indicate number and “ranging/ranges from” a first indicate number“to” a second indicate number are used herein interchangeably and aremeant to include the first and second indicated numbers and all thefractional and integral numerals therebetween.

It is appreciated that certain features of the invention, which are, forclarity, described in the context of separate embodiments, may also beprovided in combination in a single embodiment. Conversely, variousfeatures of the invention, which are, for brevity, described in thecontext of a single embodiment, may also be provided separately or inany suitable subcombination or as suitable in any other describedembodiment of the invention. Certain features described in the contextof various embodiments are not to be considered essential features ofthose embodiments, unless the embodiment is inoperative without thoseelements.

Although the invention has been described in conjunction with specificembodiments thereof, it is evident that many alternatives, modificationsand variations will be apparent to those skilled in the art.Accordingly, it is intended to embrace all such alternatives,modifications and variations that fall within the spirit and broad scopeof the appended claims.

All publications, patents and patent applications mentioned in thisspecification are herein incorporated in their entirety by referenceinto the specification, to the same extent as if each individualpublication, patent or patent application was specifically andindividually indicated to be incorporated herein by reference. Inaddition, citation or identification of any reference in thisapplication shall not be construed as an admission that such referenceis available as prior art to the present invention. To the extent thatsection headings are used, they should not be construed as necessarilylimiting.

1. An apparatus for delivering a product into a receptacle having afeeding aperture, comprising: a mixing chamber having a plurality ofinlets each configured for separately receiving at least one of aplurality of component materials and at least one outlet, said mixingchamber being configured for forming the product by mixing saidplurality of component materials and injecting the product to thefeeding aperture via said at least one outlet; and a feeding elementconfigured for being secured in a feeding channel for allowing saidinjecting.
 2. The apparatus of claim 1, wherein the distance betweensaid mixing chamber and said aperture during said injecting is less than5 centimeters.
 3. The apparatus of claim 1, wherein each said inletbeing separately connected to a hydraulic tube configured for conductingrespective said component material from a pump, wherein the distancebetween said mixing chamber and said pump is more than 10 centimeters.4. The apparatus of claim 1, wherein each said inlet being separatelyconnected to a hydraulic tube configured for conducting respective saidcomponent material from a container, wherein the distance between saidmixing chamber and said container is more than 10 centimeters.
 5. Theapparatus of claim 1, wherein at least one of said feeding element andsaid mixing chamber is detachable.
 6. The apparatus of claim 1, whereinthe distance between said mixing chamber and said aperture during saidinjecting is less than 1 centimeter.
 7. The apparatus of claim 1,wherein said feeding element is configured for containing said mixingchamber.
 8. The apparatus of claim 1, wherein the product is formed asan outcome of a chemical reaction between at least two of said pluralityof component materials.
 9. The apparatus of claim 1, wherein said mixingchamber having a volume of less than 5 cubic millimeter for performingsaid mixing.
 10. The apparatus of claim 4, further comprising a motorunit configured for motivating at least one of said mixing chamber andthe receptacle to said distance before said injecting.
 11. The apparatusof claim 10, further comprising a control unit configured forsynchronizing between said motivating and said injecting.
 12. Theapparatus of claim 1, further comprising a pumping unit configured fordirecting said plurality of component materials into said mixingchamber, said directing being controlled by at least one userinstruction.
 13. The apparatus of claim 1, further comprising a feedingelement configured for supporting the positioning of said aperture infront of said at least one outlet before said injecting.
 14. Theapparatus of claim 13, wherein said receptacle is a member of a roll ofa plurality of receptacles connected to a feeding channel, furthercomprising a motor unit configured for conducting said feeding elementin said feeding channel for supporting the positioning of respectivesaid aperture of each member of said roll.
 15. The apparatus of claim14, wherein said feeding element comprises a wedge configured forcutting said feeding channel during said conducting.
 16. A roll of aplurality of receptacles for storing a product, comprising: a pluralityof receptacles each comprises a container configured for storing theproduct of a mixture of a plurality of components and a feeding apertureconfigured for receiving the product; and a feeding channel configuredfor covering each said feeding aperture and supporting the positioningof each said feeding aperture in front of an injection unit having amixing chamber during a filling of respective said container.
 17. Thereceptacle of claim 16, wherein said feeding channel is configured forbeing cut to allow the filling of respective said container with theproduct.
 18. A method for creating a packaging element, comprising:using a feeding element for feeding a receptacle having a feedingaperture to a distance of less than 5 centimeter from an injection unithaving a mixing chamber; separately conveying a plurality of componentmaterials intosaid mixing chamber; mixing said plurality of component atsaid mixing chamber to form a mixing product; injecting the mixingproduct via said feeding aperture into said receptacle; and allowingsaid mixing product to solidified in said receptacle according to ashape of a packaged item.
 19. The method of claim 18, further comprisingusing said receptacle with said solidified mixing product for packagingsaid packaged item without closing said aperture.
 20. The method ofclaim 19, wherein said feeding comprising actuating a roll of aplurality of receptacles to allow the positioning of the receptacle infront an injection unit performing said injecting.
 21. The method ofclaim 18, further comprising: getting at least one user instruction,before said separately conveying; and separately conveying saidplurality of component materials according to said at least one userinstruction.
 22. The method of claim 18, wherein said plurality ofcomponent materials comprises isocyanate and polyol, said mixing productcomprises polyurethane.